Sintered ceramic component and a process of forming the same

ABSTRACT

A sintered ceramic component can have a final composition including at least 50 wt. % MgO and at least one desired dopant, wherein each dopant of the at least one desired dopant has a desired dopant content of at least 0.1 wt. %. All impurities (not including the desired dopant(s)) are present at a combined impurity content of less than 0.7 wt. %. A remainder can include Al 2 O 3 . The selection of dopants can allow for better control over the visual appearance of the sintered ceramic component, reduces the presence of undesired impurities that may adversely affect another part of an apparatus, or both. The addition of the dopant(s) can help to improve the sintering characteristics and density as compared to a sintered ceramic component that includes the material with no dopant and a relatively low impurity content.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication No. 62/077,583, filed Nov. 10, 2014, entitled “SinteredCeramic Component and a Process of Forming the Same”, naming asinventors Guangyong Lin et al., which is incorporated by referenceherein in its entirety.

FIELD OF THE DISCLOSURE

The following is directed to sintered ceramic components and processesof forming the same.

DESCRIPTION OF RELATED ART

Manifolds for solid oxide fuel cells can be made of magnesia-magnesiumaluminate spinel ceramics. The starting materials for the ceramics maybe commercial grade materials that include impurities that may provideundesired colors for the manifold or potentially may contaminate othercomponents within a solid oxide fuel cell. Improvements in manifoldcompositions are desired.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and are not limited by theaccompanying figures.

FIG. 1 includes a dilatometry curve for a comparative sample with arelatively high level of impurities.

FIG. 2 includes a dilatometry curve for a comparative sample with arelatively low level of impurities.

FIG. 3 includes a dilatometry curve for another comparative sample witha relatively low level of impurities.

FIG. 4 includes a dilatometry curve for a CaO-doped sample formed usingmaterial having a relatively low level of impurities.

FIG. 5 includes a dilatometry curve for a Y₂O₃-doped sample formed usingmaterial having a relatively low level of impurities.

FIG. 6 includes a dilatometry curve for a TiO₂-doped sample formed usingmaterial having a relatively low level of impurities.

FIG. 7 includes a dilatometry curve for a co-doped sample formed usingmaterial having a relatively low level of impurities.

FIG. 8 includes a dilatometry curve for co-doped samples formed usingmaterial having a relatively low level of impurities.

FIG. 9 includes a plot of relative density as a function of dopantcontent for different dopants.

Skilled artisans appreciate that elements in the figures are illustratedfor simplicity and clarity and have not necessarily been drawn to scale.For example, the dimensions of some of the elements in the figures maybe exaggerated relative to other elements to help improve understandingof embodiments of the invention. The use of the same reference symbolsin different drawings indicates similar or identical items.

DETAILED DESCRIPTION

The following description in combination with the figures is provided toassist in understanding the teachings disclosed herein. The followingdiscussion will focus on specific implementations and embodiments of theteachings. This focus is provided to assist in describing the teachingsand should not be interpreted as a limitation on the scope orapplicability of the teachings.

As used herein, color space coordinates are expressed in terms of CIE1976 (CIELAB) coordinates, L*, a*, and b*.

The term “dopant” is intended to mean a compound that is intentionallyadded to affect a property of a material to which such compound isadded.

Group numbers corresponding to columns within the Periodic Table ofElements are based on the IUPAC Periodic Table of Elements, versiondated Jan. 21, 2011.

The terms “comprises,” “comprising,” “includes,” “including,” “has,”“having,” or any other variation thereof, are intended to cover anon-exclusive inclusion. For example, a process, method, article, orapparatus that comprises a list of features is not necessarily limitedonly to those features but may include other features not expresslylisted or inherent to such process, method, article, or apparatus.Further, unless expressly stated to the contrary, “or” refers to aninclusive-or and not to an exclusive-or. For example, a condition A or Bis satisfied by any one of the following: A is true (or present) and Bis false (or not present), A is false (or not present) and B is true (orpresent), and both A and B are true (or present).

The use of “a” or “an” is employed to describe elements and componentsdescribed herein. This is done merely for convenience and to give ageneral sense of the scope of the invention. This description should beread to include one or at least one and the singular also includes theplural, or vice versa, unless it is clear that it is meant otherwise.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The materials, methods, andexamples are illustrative only and not intended to be limiting. To theextent not described herein, many details regarding specific materialsand processing acts are conventional and may be found in textbooks andother sources within the solid oxide fuel cell and ceramic arts.

An apparatus can include a sintered ceramic component. The apparatus canbe an energy generating apparatus that includes one or solid oxide fuelcells or can be a gas-to-liquid membrane system. In an embodiment, thesintered ceramic component can be a manifold to provide a gas to orremove a gas from the apparatus or can be another component that is usedin conjunction with the solid oxide fuel cell(s) or gas-to-liquidmembrane system. Such other component may be used to connect a pluralityof solid oxide fuel cells or systems to each other.

The sintered ceramic component may include a high purity magnesiamagnesium aluminate (“MMA”) that is intentionally doped with one or moreimpurities to provide good sintering properties, high density, aparticular color, if needed or desired, and not have other impuritiesthat could adversely affect the color or adversely interact with othercomponents in the apparatus.

In a particular embodiment, the sintered ceramic component can includeat least 50 wt. % MgO; at least one desired dopant, wherein each dopantof the at least one desired dopant has a desired dopant content of atleast 0.1 wt. %; all impurities are present at a combined impuritycontent of less than 0.7 wt. %; and a remainder comprising Al₂O₃.

In an embodiment desired dopant can include CaO, Y₂O₃, TiO₂, anothersuitable dopant, or any combination thereof. In another embodiment, thedesired dopant can include SrO, BaO, Sc₂O₃, La₂O₃, ZrO₂, HfO₂, V₂O₅,Nb₂O₅, Ta₂O₅, Mo₂O₃, W₂O₃, Co₂O₃, or any combination thereof. Fe₂O₃ maybe useful as a co-dopant when combined with another dopant, such as CaO.In an embodiment, the desired dopant content is at least 0.2 wt. %, atleast 0.3 wt. %, at least 0.4 wt. %, or at least 0.5 wt. %, and inanother embodiment, the desired dopant content is no greater than 5 wt.%, no greater than 3 wt. %, no greater than 2 wt. %, or no greater than1.1 wt. %. In a particular embodiment, the desired dopant content is ina range of 0.2 wt. % to 5 wt. %, 0.3 wt. % to 3 wt. %, 0.4 wt. % to 2wt. %, or 0.5 wt. % to 1.1 wt. %.

The desire dopant concentrations may be tailored more closely toparticular dopants. For CaO, the CaO content can be at least 0.2 wt. %,at least 0.3 wt. %, at least 0.4 wt. %, or at least 0.5 wt. %, or may beno greater than 3 wt. %, no greater than 2 wt. %, no greater than 1.5wt. %, or no greater than 0.95 wt. %. In a particular embodiment havingCaO, the CaO content is in a range of 0.2 wt. % to 3 wt. %, 0.3 wt. % to2 wt. %, 0.4 wt. % to 1.5 wt. %, 0.5 wt. % to 0.95 wt. %, or 0.2 wt. %to 0.5 wt. %. For Y₂O₃, the Y₂O₃ content can be at least 0.2 wt. %, atleast 0.3 wt. %, at least 0.4 wt. %, or at least 0.5 wt. %, or may be nogreater than 3 wt. %, no greater than 2 wt. %, no greater than 1.5 wt.%, or no greater than 0.95 wt. %. In a particular embodiment havingY₂O₃, the Y₂O₃ content is in a range of 0.2 wt. % to 3 wt. %, 0.3 wt. %to 2 wt. %, 0.4 wt. % to 1.5 wt. %, or 0.5 wt. % to 0.95 wt. %. ForTiO₂, the TiO₂ content can be at least 0.2 wt. %, at least 0.3 wt. %, atleast 0.4 wt. %, or at least 0.5 wt. %, or may be no greater than 3 wt.%, no greater than 2.5 wt. %, no greater than 2.0 wt. %, or no greaterthan 1.5 wt. %. In a particular embodiment having TiO₂, the TiO₂ contentis in a range of 0.2 wt. % to 3 wt. %, 0.3 wt. % to 2.5 wt. %, 0.4 wt. %to 2.0 wt. %, or 0.5 wt. % to 1.5 wt. %.

In a particular embodiment, some compounds may not be desired dopants.For example, the desired dopant may not include Cr₂O₃, NiO, CuO, or anycombination thereof. Such compounds may react with MgO or Al₂O₃ to forma different compound.

The ceramic material may be co-doped with a first dopant and a seconddopant that is different from the first dopant. The first dopant caninclude CaO, Y₂O₃, or TiO₂, and the second dopant includes CaO, Y₂O₃,TiO₂, Fe₂O₃, SrO, BaO, Sc₂O₃, La₂O₃, ZrO₂, HfO₂, V₂O₅, Nb₂O₅, Ta₂O₅,Mo₂O₃, W₂O₃, CO₂O₃, or any combination thereof. In an embodiment, thefirst dopant is present in the final composition at a higherconcentration than the second dopant, and in another embodiment, thefirst dopant is present in the final composition at a lowerconcentration than the second dopant. In a particular embodiment, acombination of the first and second dopants is in a range of 1 wt. % to9 wt. % of the final composition.

Most of the sintered ceramic component may include magnesia and alumina.In an embodiment, the composition of the sintered ceramic component canbe selected to achieve a coefficient of thermal expansion (CTE) to matchanother component to which the sintered ceramic component may becoupled. CTEs as described herein are the CTEs as measured from 25° C.to 1200° C. In conjunction with the annealing conditions disclosedabove, the CTE can be at least 9.0 ppm/° C., such as at least 10.3 ppm/°C. or at least 10.6 ppm/° C. In another embodiment, the sintered ceramiccomponent may have a CTE of no greater than 13.0 ppm/° C., such as nogreater than 12.7 ppm/° C., or no greater than 12.5 ppm/° C. In yetanother embodiment, the sintered ceramic component can have a CTE in arange of 9.0 ppm/° C. to 13.0 ppm/° C., 10.3 ppm/° C. to 12.7 ppm/° C.,or 10.6 ppm/° C. to 12.5 ppm/° C. Depending on the applications of thesintered ceramic component, the CTE of the sintered ceramic componentcan match closely to that of the material to be coupled. For example,the sintered having a CTE in a range of 11.0 ppm/° C. to 12.5 ppm/° C.is well suited for use with an SOFC. In another embodiment, the sinteredceramic component having a CTE of 10.6 ppm/° C. to 12.5 ppm/° C. can besuitable for use with a gas-to-liquid membrane system.

In another embodiment, the content may be expressed as an amount of MgOand another amount of Al₂O₃. In an embodiment, the MgO has a contentthat is at least 51 wt. %, at least 55 wt. %, or at least 60 wt. %, andin another embodiment, the MgO has a content that is no greater than 80wt. %, no greater than 75 wt. %, or no greater than 70 wt. %. In aparticular embodiment, the MgO has a content that is in a range of 51wt. % to 80 wt. %, 55 wt. % to 75 wt. %, 60 wt. % to 70 wt. %. In anembodiment the Al₂O₃ has a content that is at least 20 wt. %, at least25 wt. %, or at least 30 wt. %, and in another embodiment, the Al₂O₃ hasa content that is no greater than 49 wt. %, no greater than 45 wt. %, orno greater than 40 wt. %. In a particular embodiment, the Al₂O₃ has acontent that is in a range of 20 wt. % to 49 wt. %, 25 wt. % to 45 wt.%, 30 wt. % to 40 wt. %.

The desired dopants may help to achieve good density without having tosinter the ceramic component at too high of a temperature or havingrelatively high levels of undesired impurities. In an embodiment, thesintered ceramic component has a density that is at least 90% oftheoretical density, at least 92% of theoretical density, or at least94% of theoretical density, and in another embodiment, no greater than99.9% of theoretical density, no greater than 99.5% of theoreticaldensity, or no greater than 99.0% of theoretical density. In aparticular embodiment, the sintered ceramic component has a density in arange of 90% to 99.9% of theoretical density, 92% to 99.5% oftheoretical density, or 94% to 99% of theoretical density.

Density may also be expressed on a relative basis. The relativedensities can be expressed as a difference in percentages of theoreticaldensity. As an example, two different components have differentcompositions and are sintered under the same conditions. One of thecomponents may have a density that is 97% of theoretical density, andthe other component may have a density that is 92% of theoreticaldensity. The density of the one component is 5% higher than the densityof the other component. In an embodiment, when sintered under the sameconditions, the sintered ceramic component has a density that is atleast 3%, at least 6%, at least 9%, or at least 12% higher than adensity of a different sintered ceramic component that includes at least50 wt. % MgO, all impurities are present at a combined impurity contentof less than 0.7 wt. %, a remainder comprising Al₂O₃, and other than MgOand Al₂O₃, no other metal oxide is present at a content of at least 0.1wt. %. In another embodiment, when sintered under the same conditions,the sintered ceramic component has a density that is no greater that17%, no greater than 16%, no greater than 15%, or no greater than 14%higher than a density of a different sintered ceramic component thatincludes at least 50 wt. % MgO, all impurities are present at a combinedimpurity content of less than 0.7 wt. %, a remainder comprising Al₂O₃,and other than MgO and Al₂O₃, no other metal oxide is present at acontent of at least 0.1 wt. %. In a particular embodiment, when sinteredunder the same conditions, the sintered ceramic component has a densitythat is in a range of 3% to 17%, 6% to 16%, 9% to 15% higher than adensity of a different sintered ceramic component that includes at least50 wt. % MgO, all impurities are present at a combined impurity contentof less than 0.7 wt. %, a remainder comprising Al₂O₃, and, other thanMgO and Al₂O₃, other metal oxide is present at a content of at least 0.1wt. %.

The color of the sintered ceramic component can be expressed in CIELABcoordinates. In an embodiment, the sintered ceramic component has L* isat least 65, at least 80, or at least 88; a* is in a range of −1.0 to+7.0, −0.3 to +2.0, or −0.2 to +1.5; and b* is in a range of +4.0 to+20, +4.2 to +15, or +4.4 to +12. A user of the sintered ceramiccomponent may desire that the sintered ceramic component have arelatively white appearance. In an embodiment, the sintered ceramiccomponent has L* is at least 85, at least 88, or at least 89; a* is in arange of −1.0 to +1.0, −0.3 to +0.7, or −0.2 to +0.4; and b* is in arange of +4.0 to +9.0 +4.2 to +8.5, or +4.4 to +8.0. Contamination,rather than color, may more of a concern. Alternatively, a user maydesire that the sintered ceramic component have a yellow or dark yellowappearance. In a particular embodiment, the sintered ceramic componenthas L* is at least 65, at least 70, or at least 75; a* is in a range of0.0 to +7.0 +0.5 to +6.6 or +0.7 to +6.0; and b* is in a range of +5.0to +20, +6.0 to +17, or +6.5 to +15.

A process of forming the sintered ceramic compound can include obtainingappropriate powders that make up the sintered ceramic compound. Sourcesfor the MgO and Al₂O₃ may include those particular compounds or caninclude other sources. In an embodiment, powders of MgO and spinel(MgAl₂O₄) may be used. In another embodiment, a powder including a fusedMgO-containing MgAl₂O₄ may be used. Thus, the relative amounts of MgOand Al₂O₃ may be controlled in a variety of ways. One or more desireddopants can be added. Any of the dopants previously described may beadded at the amounts previously described. In another embodiment, thedopants may be added using a different compound. For example, CaCO₃ maybe used instead of or in conjunction with CaO. During the formationsequence, CaCO₃ decomposes into CaO and CO₂, thus, leaving CaO in thesintered ceramic component. The amount of CaCO₃ in the starting materialmay be adjusted to account for a higher molecular weight as compared toCaO. The powders may be agglomerated, milled, subjected to anotherparticle size changing operation, or the like, if needed or desired. Inan embodiment, the powders may have different particle sizes for thesame material or different materials. The powders for the ceramiccomponent can be combined before, during or after the powders have anappropriate particle size. The powders can include at least 50 wt. %MgO; at least one desired dopant, wherein each dopant of the at leastone desired dopant has a desired dopant content of at least 0.1 wt. %;all impurities are present at a combined impurity content of less than0.7 wt. %; and a remainder comprising Al₂O₃.

The process can further include combining the powders and a binder,another material, or a combination thereof to form a green mixture. Thebinder or other material can include a polyacrylate, a polyvinylalcohol, a polyethylene glycol, another suitable material to aid inmixing or binding the powders, or any combination thereof. A solvent canbe used if needed or desired. The solvent can include water, alcohol,glycol, another suitable liquid that can aid in allow for better mixingof the powders and the binder, or any combination thereof. One or moreadditional materials can be added if needed or desire. Such additionalmaterials can include a surfactant, a polyvinyl alcohol, a polyvinylbutyral, a butyl benzyl phthalate, a fish oil, or any combinationthereof.

The method can further include shaping the green mixture having a shapecorresponding to the sintered ceramic component. The shape can be largerthan the final sintered ceramic component due to densification during asubsequent sintering operation.

The object can be heated during one or more operations to form thesintered ceramic component. The object may be heated to a firsttemperature to drive out volatile components, such as the solvent. Thetemperature can be in a range of 25° C. to 150° C. for a time in a rangeof 1 hour to 4 hours. The pressure during volatile component drive offcan be at atmospheric pressure or under vacuum pressure. If vacuumpressure is used, the pressure should not be so low as to cause anycracks, fractures, or other defects to form in the object. Thetemperature can be increased to burn out the binder and any othercarbon-containing material. The temperature for the burn out operationcan be in a range of 150° C. to 650° C. for a time in a range of 5 to 48hours. The pressure for the burn out can be performed at atmosphericpressure, at a higher pressure than atmospheric pressure, or undervacuum. Gas evolved during burn out may be difficult to remove if thepressure is too higher. In an embodiment, the pressure may not begreater than 30 kPa. If the pressure is too low, cracks, fractures, orother defects may form in the object. In an embodiment, the pressure maybe at least 0.2 kPa-abs. In another embodiment, pressures higher orlower than recited may be used. The burn out can be performed using anoxygen-containing gas, such as O₂, ozone, N₂O, NO, or the like. O₂ maybe in the form of air (21 vol. % O₂) or may be provided at aconcentration different from air. Air may be flown into the furnaceduring the burn out of the binder or other carbon-containing material.

The temperature can be further increased to form the sintered ceramiccomponent. The one or more dopants in the object can help to lower thesintering temperature of the material. Thus, the sintering can beperformed lower than the magnesia-alumina material by itself. Thesintering can be performed at a temperature less than 1600° C. Withoutdopant, the magnesia-alumina material will not properly sintered untilthe material is well above 1600° C., such as closer to 1800° C. In anembodiment, sintering is performed at a temperature of at least 1200°C., at least 1250° C., or at least 1300° C., and in another embodiment,sintering is performed at a temperature no greater than 1575° C., nogreater than 1500° C., or no greater than 1450° C. In a particularembodiment, sintering is performed at a temperature in a range of 1200°C. to 1575° C., 1250° C. to 1550° C., or 1300° C. to 1450° C. Thesintering may be performed for a time to allow sufficient sintering anddensification to occur. In an embodiment, the time is at least 1 hour,at least 2 hours, or at least 3 hours, and in another embodiment, thetime may be no greater than 50 hours, no greater than 20 hours, or nogreater than 9 hours. In a particular embodiment, the time is in a rangeof 1 hour to 50 hours, 2 hours to 20 hours, or 3 hours to 9 hours.Sintering can be performed at a pressure of at least atmosphericpressure (also referred to as pressureless sintering) to a relativelyhigh pressure. The pressure can be applied in the form of pressurizedgas, hot pressing or hot isostatic pressing. Sintering can be performedusing an oxygen-containing gas, such as O₂, ozone, N₂O, NO, or the like.O₂ may be in the form of air (21 vol. % O₂) or may be provided at aconcentration different from air.

Although many values of sintering parameters are described, afterreading this specification, skilled artisans will appreciate that valuesoutside those disclosed may be used without deviating from the conceptsherein. The operations described above may be performed during a singleheating cycle or during different heating cycles. Additional operationsmay be performed during heating. For example, during cooling aftersintering, the sintered ceramic component may be allowed to soak at atemperature to reduce the likelihood of building up too much strainwithin the component. Controlling the heating rate and cooling rate mayalso be used to reduce the likelihood of building up too much strain andcracking within the component.

The sintered ceramic component is well suited for use as a gas manifoldor another component used in conjunction with a solid oxide fuel cell, agas-to-liquid membrane system, or for another application where thesintered ceramic component configured such that it withstand exposure toa relatively high (i.e., greater than 400° C.) during normal operatingconditions of an apparatus.

Many different aspects and embodiments are possible. Some of thoseaspects and embodiments are described herein. After reading thisspecification, skilled artisans will appreciate that those aspects andembodiments are only illustrative and do not limit the scope of thepresent invention. Additionally, those skilled in the art willunderstand that some embodiments that include analog circuits can besimilarly implemented using digital circuits, and vice versa.Embodiments may be in accordance with any one or more of the items aslisted below.

Embodiment 1

A sintered ceramic component having a final composition can include atleast 50 wt. % MgO; at least one desired dopant, wherein each dopant ofthe at least one desired dopant has a desired dopant content of at least0.1 wt. %; all impurities are present at a combined impurity content ofless than 0.7 wt. %; and a remainder including Al₂O₃.

Embodiment 2

A process of forming a sintered ceramic component can include:

-   -   combining a binder and at least one powder to form a green        mixture, wherein the at least one powder includes at least 50        wt. % MgO; at least one desired dopant, wherein each dopant of        the at least one desired dopant has a desired dopant content of        at least 0.1 wt. %; all impurities are present at a combined        impurity content of less than 0.7 wt. %; and a remainder        including Al₂O₃;    -   shaping the green mixture to form an object having a shape        corresponding to the sintered ceramic component; and    -   sintering the object to form the sintered ceramic component        having a final composition, wherein sintering is performed at a        temperature less than 1600° C., and the sintered ceramic        component has a density that is at least 90% of theoretical        density.

Embodiment 3

The process of Embodiment 2, further including combining a first powderincluding MgO, a second powder including Al₂O₃, and a third powderincluding the at least one desired dopant before adding the binder.

Embodiment 4

The process of Embodiment 2, further including combining a first powderincluding MgO and Al₂O₃ and a second powder including the at least onedesired dopant before adding the binder.

Embodiment 5

The process of Embodiment 4, wherein the first powder includes a fusedMgO-containing MgAl₂O₄ material.

Embodiment 6

The process of any one of Embodiments 2 to 5, wherein sintering isperformed at a temperature of at least 1200° C., at least 1250° C., orat least 1300° C.

Embodiment 7

The process of any one of Embodiments 2 to 6, wherein sintering isperformed at a temperature no greater than 1575° C., no greater than1500° C., or no greater than 1450° C.

Embodiment 8

The process of any one of Embodiments 2 to 7, wherein sintering isperformed at a temperature in a range of 1200° C. to 1575° C., 1250° C.to 1550° C., or 1300° C. to 1450° C.

Embodiment 9

The process of any one of Embodiments 2 to 8, further including burningout the binder before sintering the object.

Embodiment 10

The process of any one of Embodiments 2 to 9, wherein the at least onedesired dopant within the combined powders is CaCO₃.

Embodiment 11

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein the desired dopant content is at least0.2 wt. %, at least 0.3 wt. %, at least 0.4 wt. %, or at least 0.5 wt.%.

Embodiment 12

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein the desired dopant content is no greaterthan 5 wt. %, no greater than 3 wt. %, no greater than 2 wt. %, or nogreater than 1.1 wt. %.

Embodiment 13

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein the desired dopant content is in a rangeof 0.2 wt. % to 5 wt. %, 0.3 wt. % to 3 wt. %, 0.4 wt. % to 2 wt. %, or0.5 wt. % to 1.1 wt. %.

Embodiment 14

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein the at least one desired dopant includesCaO.

Embodiment 15

The sintered ceramic component or the process of Embodiment 14, whereinthe CaO content is at least 0.2 wt. %, at least 0.3 wt. %, at least 0.4wt. %, or at least 0.5 wt. %.

Embodiment 16

The sintered ceramic component or the process of Embodiment 14 or 15,wherein the CaO content is no greater than 3 wt. %, no greater than 2wt. %, no greater than 1.5 wt. %, or no greater than 0.95 wt. %.

Embodiment 17

The sintered ceramic component or the process of Embodiments 14, 15, or16, wherein the CaO content is in a range of 0.2 wt. % to 3 wt. %, 0.3wt. % to 2 wt. %, 0.4 wt. % to 1.5 wt. %, 0.5 wt. % to 0.95 wt. %, or0.2 wt. % to 0.5 wt. %.

Embodiment 18

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein the at least one desired dopant includesY₂O₃.

Embodiment 19

The sintered ceramic component of Embodiment 18, wherein the Y₂O₃content is at least 0.2 wt. %, at least 0.3 wt. %, at least 0.4 wt. %,or at least 0.5 wt. %.

Embodiment 20

The sintered ceramic component of Embodiment 18 or 19, wherein the Y₂O₃content is no greater than 3 wt. %, no greater than 2 wt. %, no greaterthan 1.5 wt. %, or no greater than 0.95 wt. %.

Embodiment 21

The sintered ceramic component of Embodiments 18, 19, or 20, wherein theY₂O₃ content is in a range of 0.2 wt. % to 3 wt. %, 0.3 wt. % to 2 wt.%, 0.4 wt. % to 1.5 wt. %, or 0.5 wt. % to 0.95 wt. %.

Embodiment 22

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein the at least one desired dopant includesTiO₂.

Embodiment 23

The sintered ceramic component of Embodiment 22, wherein the TiO₂content is at least 0.2 wt. %, at least 0.3 wt. %, at least 0.4 wt. %,or at least 0.5 wt. %.

Embodiment 24

The sintered ceramic component of Embodiment 22 or 23, wherein the TiO₂content is no greater than 3 wt. %, no greater than 2.5 wt. %, nogreater than 2.0 wt. %, or no greater than 1.5 wt. %.

Embodiment 25

The sintered ceramic component of Embodiments 22, 23, or 24, wherein theTiO₂ content is in a range of 0.2 wt. % to 3 wt. %, 0.3 wt. % to 2.5 wt.%, 0.4 wt. % to 2.0 wt. %, or 0.5 wt. % to 1.5 wt. %.

Embodiment 26

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein the at least one desired dopant includesSrO, BaO, Sc₂O₃, La₂O₃, ZrO₂, HfO₂, V₂O₅, Nb₂O₅, Ta₂O₅, Mo₂O₃, W₂O₃,Co₂O₃, or any combination thereof.

Embodiment 27

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein the at least one desired dopant does notinclude Cr₂O₃, NiO, or CuO.

Embodiment 28

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein the at least one dopant includes a firstdopant and a second dopant.

Embodiment 29

The sintered ceramic component or the process of Embodiment 28, whereinthe first dopant includes CaO, Y₂O₃, or TiO₂.

Embodiment 30

The sintered ceramic component or the process of Embodiment 28 or 29,wherein the second dopant includes CaO, Y₂O₃, TiO₂, Fe₂O₃, SrO, BaO,Sc₂O₃, La₂O₃, ZrO₂, HfO₂, V₂O₅, Nb₂O₅, Ta₂O₅, MO₂O₃, W₂O₃, or CO₂O₃.

Embodiment 31

The sintered ceramic component or the process of any one of Embodiments28 to 30, wherein the first dopant is present in the final compositionat a higher concentration than the second dopant.

Embodiment 32

The sintered ceramic component or the process of any one of Embodiments28 to 31, wherein the first dopant is present in the final compositionat a lower concentration than the second dopant.

Embodiment 33

The sintered ceramic component or the process of any one of Embodiments28 to 32, wherein a combination of the first and second dopants are in arange of 1 wt. % to 9 wt. % of the final composition.

Embodiment 34

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein MgO has a content that is at least 51 wt.%, at least 55 wt. %, or at least 60 wt. %.

Embodiment 35

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein MgO has a content that is no greater than80 wt. %, no greater than 75 wt. %, or no greater than 70 wt. %.

Embodiment 36

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein MgO has a content that is in a range of51 wt. % to 80 wt. %, 55 wt. % to 75 wt. %, 60 wt. % to 70 wt. %.

Embodiment 37

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein Al₂O₃ has a content that is at least 20wt. %, at least 25 wt. %, or at least 30 wt. %.

Embodiment 38

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein Al₂O₃ has a content that is no greaterthan 49 wt. %, no greater than 45 wt. %, or no greater than 40 wt. %.

Embodiment 39

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein Al₂O₃ has a content that is in a range of20 wt. % to 49 wt. %, 25 wt. % to 45 wt. %, 30 wt. % to 40 wt. %.

Embodiment 40

The sintered ceramic component or the process of any one of thepreceding Embodiment, wherein the sintered ceramic component is a gasmanifold.

Embodiment 41

An apparatus including the gas manifold of Embodiment 38, wherein theapparatus is a solid oxide fuel cell, and the gas manifold is fluidlycoupled to an electrode of the solid oxide fuel cell.

Embodiment 42

The sintered ceramic component or the process of any one of theEmbodiments 1 to 39, wherein the sintered ceramic component is acomponent of a gas-to-liquid membrane system.

Embodiment 43

The sintered ceramic component or the process of any one of precedingEmbodiments, wherein the sintered ceramic component has the followingCIELAB coordinates:

L* is at least 65, at least 80, or at least 88;

a* is in a range of −1.0 to +7.0, −0.3 to +2.0, or −0.2 to +1.5; and

b* is in a range of +4.0 to +20, +4.2 to +15, or +4.4 to +12.

Embodiment 44

The sintered ceramic component or the process of any one of thepreceding Embodiments, wherein the sintered ceramic component has thefollowing CIELAB coordinates:

L* is at least 85, at least 88, or at least 89;

a* is in a range of −1.0 to +1.0, −0.3 to +0.7, or −0.2 to +0.4; and

b* is in a range of +4.0 to +9.0 +4.2 to +8.5, or +4.4 to +8.0.

Embodiment 45

The sintered ceramic component or the process of any one of Embodiments1 to 43, wherein the sintered ceramic component has the following CIELABcoordinates:

L* is at least 65, at least 70, or at least 75;

a* is in a range of 0.0 to +7.0 +0.5 to +6.6 or +0.7 to +6.0; and

b* is in a range of +5.0 to +20, +6.0 to +17, or +6.5 to +15.

Embodiment 46

The sintered ceramic component or the process of any of the precedingEmbodiments, wherein the sintered ceramic component has a density thatis at least 3%, at least 6%, at least 9%, or at least 12% higher than adifferent sintered ceramic component that includes at least 50 wt. %MgO, all impurities are present at a combined impurity content of lessthan 0.7 wt. %, a reminder including Al₂O₃, and other than MgO andAl₂O₃, no other metal oxide is present at a content of at least 0.1 wt.%.

Embodiment 47

The sintered ceramic component or the process of any of the precedingEmbodiments, wherein the sintered ceramic component has a density thatis no greater that 17%, no greater than 16%, no greater than 15%, or nogreater than 14% higher than a different sintered ceramic component thatincludes at least 50 wt. % MgO, all impurities are present at a combinedimpurity content of less than 0.7 wt. %, a remainder including Al₂O₃,and other than MgO and Al₂O₃, no other metal oxide is present at acontent of at least 0.1 wt. %.

Embodiment 48

The sintered ceramic component or the process of any of the precedingEmbodiments, wherein the sintered ceramic component has a density thatis in a range of 3% to 17%, 6% to 16%, 9% to 15% higher than a differentsintered ceramic component that includes at least 50 wt. % MgO, allimpurities are present at a combined impurity content of less than 0.7wt. %, a remainder including Al₂O₃, and, other than MgO and Al₂O₃, noother metal oxide is present at a content of at least 0.1 wt. %.

Embodiment 49

The sintered ceramic component or the process of any of the precedingEmbodiments, wherein the sintered ceramic component has a coefficient ofthermal expansion from 25° C. to 1200° C. of at least 9.0 ppm/° C., atleast 10.3 ppm/° C., or at least 10.6 ppm/° C.

Embodiment 50

The sintered ceramic component or the process of any of the precedingEmbodiments, wherein the sintered ceramic component has a coefficient ofthermal expansion from 25° C. to 1200° C. of no greater than 13.0 ppm/°C., no greater than 12.7 ppm/° C., or no greater than 12.5 ppm/° C.

Embodiment 51

The sintered ceramic component or the process of any of the precedingEmbodiments, wherein the sintered ceramic component has a coefficient ofthermal expansion from 25° C. to 1200° C. in a range of 9.0 ppm/° C. to13.0 ppm/° C., 10.3 ppm/° C. to 12.7 ppm/° C., or 10.6 ppm/° C. to 12.5ppm/° C.

EXAMPLES

The examples presented below demonstrate that sintered ceramiccomponents having compositions as described above may be formed atsintering temperatures that are less than 1600° C. and achieve desireddensities and visible appearances. The sintered ceramic components mayhave different colors depending on the dopants and dopant concentrationsselected. Samples were generated for analysis of sintering temperatures,densities when sintered at 1550° C. for 4 hours, and color informationof the sintered materials.

1. Composition of Samples and Annealing

Samples were generated with different compositions. One sample was madeusing conventional commercial-grade starting materials that wererelatively high in impurities and is referred to as the Impure Sample.Samples were made with starting materials that had relatively lowimpurity levels and are referred to the Pure 1 Sample and the Pure 2Sample. Tables 1 and 2 below include particle size distributions and thecompositions of the Impure and Pure 1 and 2 Samples. For particle sizedistributions, d₁₀, d₅₀, and d₉₀ represent the 10^(th) percentile,50^(th) percentile, and the 90^(th) percentile of the Impure and PureSamples.

TABLE 1 Particle Size Distribution of the Impure and Pure Samples Sampled₁₀ (μm) d₅₀ (μm) d₉₀ (μm) Impure Sample 0.13 2.65 5.25 Pure 1 Sample0.46 2.82 4.98 Pure 2 Sample 0.22 2.81 6.91

TABLE 2 Composition of Impure and Pure Samples MgO Al₂O₃ CaO Y₂O₃ TiO₂ZrO₂ ^(a) SiO₂ Na₂O Sample wt. % wt. % ppm ppm ppm ppm ppm ppm Impure64.6 35.1 6100 160 124 1600 1100 600 Pure 1 65.2 34.6 645 <5 10 150 120140 Pure 2 66.4 35.0 765 20 60 2600 190 65 ^(a)—ZrO₂ reported is thecombination of ZrO₂ and HfO₂

Other samples were generated using the starting materials with therelatively low impurity levels and had dopants at differentconcentrations added to such starting materials. In particular, dopedsamples below were generated using the material used to form the Pure 1Sample, except for samples doped or co-doped with TiO₂ and the Y1-Ca0.5Sample, each of which were generated using the material used to form thePure 2 Sample. Below are tables with samples and the dopingconcentrations.

TABLE 3 CaO-doped Samples (Doped from material used for Pure 1 Sample)Sample CaO vol. % CaO wt. % CaO 0.14 0.14 0.130 CaO 0.25 0.25 0.235 CaO0.28 0.28 0.262 CaO 0.42 0.42 0.393 CaO 0.50 0.50 0.469 CaO 0.56 0.560.524 CaO 0.75 0.75 0.704 CaO 1.00 1.00 0.939

TABLE 4 Y₂O₃-doped Samples (Doped from material used for Pure 1 Sample)Sample Y₂O₃ vol. % Y₂O₃ wt. % Y₂O₃ 1% 1 1.398 Y₂O₃ 2% 2 2.784 Y₂O₃ 3% 34.160 Y₂O₃ 4% 4 5.524

TABLE 5 TiO₂-doped Samples (Doped from material used for Pure 2 Sample)Sample TiO₂ vol. % TiO₂ wt. % TiO₂ 0.25 0.25 0.296 TiO₂ 0.50 0.50 0.592TiO₂ 0.75 0.75 0.887 TiO₂ 1.00 1.00 1.183

TABLE 6 Co-Doped Samples Y₂O₃ or TiO₂ Y₂O₃ or TiO₂ CaO Sample vol. % wt.% CaO vol. % wt. % Y1—Ca0.5 1.00 1.398 0.5 0.467 Y2.22—Ca0.84 2.22 3.0830.84 0.779 Ti0.5—Ca0.5 0.50 0.592 0.50 0.469 Ti1—Ca0.5 1.00 1.183 0.500.469

After preparing the samples, samples were heated to 1600° C. at a rateof 10° C./minute to obtain data for dilatometry curves. Other sampleswere heated to 1550° C. for 4 hours in air to obtain densification data.

2. Experimental Data

Dilatometry curves were generated for the samples and are included inFIGS. 1 to 8, which have % dL/dT as a function of temperature during theheating to 1600° C. FIG. 1 includes a dilatometry curve of the ImpureSample. FIGS. 2 and 3 include dilatometry curves of the Pure 1 and Pure2 Samples. FIGS. 4 to 8 include the dilatometry curves for selecteddoped and co-doped samples.

Densification was performed at 1550° C. for 4 hours in air except asexplicitly noted. FIG. 9 includes a plot of densification, expressed aspercentage of theoretical density as a function of doping concentrationfor particular dopants. The material for the Impure Sample has typicallyhas a densification in a range of 95.7% to 98.8%. Table 7 includes thedensification data.

TABLE 7 Densification (1550° C. for 4 hours in air) Relative DensitySample (% of Theoretical Density) Impure 95.7 to 98.8 Pure 1 83.0 Pure 288.7 CaO 0.14 95.6 CaO 0.25 95.6 CaO 0.28 95.2 CaO 0.42 97.0 CaO 0.595.6 CaO 0.56 95.6 CaO 0.75 95.5 CaO 1.0 95.0 Y₂O₃ 1% 91.8 Y₂O₃ 2% 90.6Y₂O₃ 3% 88.8 Y₂O₃ 4% 87.6 TiO₂ 0.25 91.0 TiO₂ 0.50 92.1 TiO₂ 0.75 94.7TiO₂ 1.00 93.7 Y2.2—Ca0.84 97.4 Y1.0—Ca0.5 95.1 Ti0.5—Ca0.5 95.4Ti1.0—Ca0.5 96.2

Samples were checked for their visible appearance to the human eye.Samples were inspected after densification, and after annealing thedensified samples were annealed at 800° C. for 72 hours in air. Table 8includes the visual appearance information.

TABLE 8 Visual Appearance Appearance after Appearance afterdensification and Sample densification further anneal Impure Pure 1White White Pure 2 White White CaO White White Y₂O₃ Dark Yellow LightYellow TiO₂ White White CaO and Y₂O₃ Dark Yellow Darker Yellow (Brown)CaO and TiO₂ White White

Samples after densification were analyzed for their color in terms ofcolor space coordinates L*, a* and b*. YI E313 [D65/10] is yellowness asmeasured using ASTM standard E313 using the version in effect as of thefiling date of this specification. D65 is the standard illuminant, and10 refers to the angle of insert light. Table 9 includes color spacecoordinate and yellowness information.

TABLE 9 Color Space Coordinates and Yellowness YI E313 Sample L* a* b*[D65/10] Impure 78.21 3.05 18.85 40.95 Pure 1 96.77 0.46 3.86 7.53 Pure2 96.41 0.38 4.22 8.16 CaO 0.14 92.46 0.19 4.89 9.56 CaO 0.25 90.05 0.15.62 11.10 CaO 0.28 91.3 0.06 5.65 10.98 CaO 0.42 89.47 0.11 6.91 13.61CaO 0.5 89.3 0.05 5.68 11.24 CaO 0.56 90.16 −0.16 5.64 10.90 CaO 0.7590.28 −0.05 6.45 12.51 CaO 1.0 90.02 −0.03 7.73 14.95 Y₂O₃ 1 84.66 3.4912.58 27.91 Y₂O₃ 2 75.46 4.32 14.72 35.50 Y₂O₃ 3 70.7 5.69 13.92 37.06Y₂O₃ 4 65.53 6.55 11.47 34.81 TiO₂ 0.25 96.12 0.32 4.74 9.08 TiO₂ 0.5095.33 0.32 5.71 10.90 TiO₂ 0.75 93.87 −0.01 6.11 11.52 TiO₂ 1.00 92.69−0.06 6.23 11.83 Y2.2—Ca0.84 78.81 5.95 18.03 41.95 Y1.0—Ca0.5 92.430.20 5.03 9.82 Ti0.5—Ca0.5 90.72 −0.98 10.65 19.39 Ti1.0—Ca0.5 90.41−0.66 11.97 22.06

3. Observations

The Impure Sample has good sintering and densification properties;however, the Impure Sample has a high level of impurities due tocommercial-grade starting materials being used. The Pure 1 Sample has awhite appearance, but the density is 83% when exposed to 1550° C. for 4hours. In some applications, a densification of at least 95% may beneeded or desired. Thus, sintering would need to be performed at atemperature greater than 1600° C. or the exposure at 1600° C. or lowerwould be long, both of which are undesired. The Pure 1 and 2 Sampleshave very low levels of impurities and have a white appearance. Ascompared to Pure 1 Sample, the Pure 2 Sample has a significantly higherZrO₂ content; however, even at such a ZrO₂ content, the Pure 2 Samplestill does not have sufficiently good sintering and density properties.

The CaO-doped samples have a white appearance and good sinteringcharacteristics. After sintering at 1550° C. for 4 hours in air, thedensity is over 95% of theoretical density at a CaO content of 0.13 wt.% and higher. Overall, the density is the highest in a range of 0.40 wt.% to 0.55 wt. % CaO content. Higher CaO can be used; however, the highercontent levels increase manufacturing costs and does not further improvedensity.

The Y2O3 1 sample has a white appearance. As the Y₂O₃ content increasesthe sample becomes more yellow. At 2 vol. % and higher, the Y₂O₃-dopedsamples have a dark yellow appearance that can change to yellow whenexposed at 800° C. for 72 hours in air. The sintering characteristicsare good, but not as good as the CaO-doped samples. Based on the data,the density increases until the Y₂O₃ content reaches 1.40 wt. % and thendecreases.

The TiO₂-doped samples have a white appearance. The sinteringcharacteristics are good, and between the sintering characteristics ofthe CaO-doped samples and the Y₂O₃-doped samples. Based on the data, thedensity increases until the TiO₂ content reaches 0.9 wt. % and thendecreases.

Y1.0-Ca0.5-co-doped samples have a white appearance and with a densityof 95.1%, the same as CaO 0.5 singly doped samples both in density andin appearance while higher than Y 1.0 (1.0 Vol %.Y₂O₃) singly dopedsamples (91.8%). The Y2.2-Ca0.84 has a higher density (97.4%) than thedensity of Y or Ca samples, regardless of Y or Ca content in theircorresponding singly doped samples, and the Y2.2-Ca0.84 co-doped sampleshave dark yellow appearance, the same as Y₂O₃ doped samples with a Y₂O₃content of 2.78 wt % and higher. The data indicates that a certainamount of Y₂O₃ and CaO doping can be used if both color and density areimportant in some applications. Both Ti0.5-Ca0.5 and Ti1.0-Ca0.5co-doped samples have similar results in the both density and appearanceas the CaO 0.5 singly doped samples but higher than Ti 0.5 and Ti 1.0singly doped samples for the density.

Note that not all of the activities described above in the generaldescription or the examples are required, that a portion of a specificactivity may not be required, and that one or more further activitiesmay be performed in addition to those described. Still further, theorder in which activities are listed is not necessarily the order inwhich they are performed.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

The specification and illustrations of the embodiments described hereinare intended to provide a general understanding of the structure of thevarious embodiments. The specification and illustrations are notintended to serve as an exhaustive and comprehensive description of allof the elements and features of apparatus and systems that use thestructures or methods described herein. Separate embodiments may also beprovided in combination in a single embodiment, and conversely, variousfeatures that are, for brevity, described in the context of a singleembodiment, may also be provided separately or in any subcombination.Further, reference to values stated in ranges includes each and everyvalue within that range. Many other embodiments may be apparent toskilled artisans only after reading this specification. Otherembodiments may be used and derived from the disclosure, such that astructural substitution, logical substitution, or another change may bemade without departing from the scope of the disclosure. Accordingly,the disclosure is to be regarded as illustrative rather thanrestrictive.

What is claimed is:
 1. A sintered ceramic component having a finalcomposition comprising: at least 50 wt. % MgO; at least one desireddopant, wherein each dopant of the at least one desired dopant has adesired dopant content of at least 0.1 wt. %; all impurities are presentat a combined impurity content of less than 0.7 wt. %; and a remaindercomprising Al₂O₃.
 2. The sintered ceramic component of claim 1, whereinthe at least one desired dopant includes CaO.
 3. The sintered ceramiccomponent of claim 2, wherein the CaO content is at least 0.2 wt. %. 4.The sintered ceramic component of claim 1, wherein the at least onedesired dopant includes Y₂O₃.
 5. The sintered ceramic component of claim4, wherein the Y₂O₃ content is no greater than 3 wt. %.
 6. The sinteredceramic component of claim 1, wherein the at least one desired dopantincludes TiO₂.
 7. The sintered ceramic component of claim 6, wherein theTiO₂ content is no greater than 3 wt. %
 8. The sintered ceramiccomponent of claim 1, wherein the at least one dopant includes a firstdopant and a second dopant.
 9. The sintered ceramic component of claim1, wherein MgO has a content that is in a range of 51 wt. % to 80 wt. %.10. The sintered ceramic component of claim 1, wherein Al₂O₃ has acontent that is in a range of 20 wt. % to 49 wt. %.
 11. The sinteredceramic component of claim 1, wherein the sintered ceramic component isa gas manifold.
 12. The sintered ceramic component of claim 1, whereinthe sintered ceramic component is a component of a gas-to-liquidmembrane system.
 13. The sintered ceramic component of claim 1, whereinthe sintered ceramic component has a coefficient of thermal expansionfrom 25° C. to 1200° C. in a range of 9.0 ppm/° C. to 13.0 ppm/° C. 14.A process of forming a sintered ceramic component comprising: combininga binder and at least one powder to form a green mixture, wherein the atleast one powder includes: at least 50 wt. % MgO; at least one desireddopant, wherein each dopant of the at least one desired dopant has adesired dopant content of at least 0.1 wt. %; all impurities are presentat a combined impurity content of less than 0.7 wt. %; and a remaindercomprising Al₂O₃; shaping the green mixture to form an object having ashape corresponding to the sintered ceramic component; and sintering theobject to form the sintered ceramic component having a finalcomposition, wherein sintering is performed at a temperature less than1600° C., and the sintered ceramic component has a density that is atleast 90% of theoretical density.
 15. The process of claim 14, whereinsintering is performed at a temperature no greater than 1575° C.
 16. Theprocess of claim 14, wherein the at least one desired dopant includesCaO.
 17. The process of claim 14, wherein the at least one desireddopant includes Y₂O₃.
 18. The process of claim 14, wherein the at leastone desired dopant includes TiO₂.
 19. The process of claim 14, whereinthe at least one dopant includes a first dopant and a second dopant. 20.The process of claim 14, wherein the sintered ceramic component has acoefficient of thermal expansion from 25° C. to 1200° C. in a range of9.0 ppm/° C. to 13.0 ppm/° C., 10.3 ppm/° C. to 12.7 ppm/° C., or 10.6ppm/° C. to 12.5 ppm/° C.